Air Lift 60828HD Installation guide

Brand: Air Lift

Model: 60828HD

Type: Installation guide

For maximum effectiveness and safety,

please read these instructions completely

before proceeding with installation.

Failure to read these instructions can result in an

incorrect installation.

MN-1081 • (021901) • ECR 9227

INSTALLATION GUIDE

Kit 60828HD

RAM 1500

Air Lift 1000 HD

TABLE OF CONTENTS

Introduction .......................................2

Notation Explanation ................................................2

Installing the Air Lift 1000 HD Kit ......................3

Hardware List .....................................................3

Tools List .........................................................3

Getting Started ....................................................3

Installing the Air Springs .............................5

Installing the Air Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Before Operating ...................................8

Installation Checklist ................................................8

Maintenance and Use Guidelines ......................................8

Minimum and Maximum Air Pressure ...................................8

Limited Warranty and Return Policy ....................................8

MN-1081

Air Lift 1000 HD

Introduction

The purpose of this publication is to assist with the installation and maintenance of the

Air Lift 1000 HD air spring kit.

It is important to read and understand the entire installation guide before beginning

installation or performing any maintenance, service or repair. The information here

includes a hardware list, tools list, step-by-step installation information, maintenance

guidelines and a checklist for after completing the installation.

Air Lift Company reserves the right to make changes and improvements to its products

and publications at any time. Contact Air Lift Company at (800) 248-0892 or go online at

www.airliftcompany.com for the latest version of this manual.

NOTATION EXPLANATION

Hazard notations appear in various locations in this publication. Information which is

highlighted by one of these notations must be observed to help minimize risk of personal

injury or possible improper installation which may render the vehicle unsafe. The following

definitions explain the use of these notations as they appear throughout this guide.

INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY

OR DEATH.

INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE

PERSONAL INJURY OR DEATH.

INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO

THE MACHINE OR MINOR PERSONAL INJURY.

DANGER

CAUTION

WARNING

MN-1081

Air Lift 1000 HD

Item Part # Description ............................................... Qty

A 48178 Air spring ............................................................... 2

B 09128 Air spring protector ............................................... 2

C 20937 Air line .................................................................15 ft

D 10466 Zip ties .................................................................. 6

E 21230 Valve cap ............................................................... 2

F 21233 5/16” Hex nut ........................................................ 4

G 21234 Rubber washer ...................................................... 2

H 18411 Star washer ........................................................... 2

I 18501 M8 Flat washer ..................................................... 2

J 21236 Tee fitting............................................................... 1

K 21455 Schrader valve ...................................................... 2

L 10638 Air line clamp ........................................................ 6

M 21730 Straight pump connector ...................................... 2

HARDWARE LIST TOOLS LIST

Description ...................................................... Qty

Standard and metric open-end/box wrenches ..........SET

Adjustable wrench .......................................................... 1

China or tire marker (white crayon) ................................ 1

Ratchet ........................................................................... 1

Pliers ............................................................................... 1

Standard & metric, regular & deep-well sockets ........ SET

5/16” drill bit (very sharp) ............................................... 1

Heavy-duty drill .............................................................. 1

Hose cutter, razor blade, or sharp knife ......................... 1

Hoist or Jack .................................................................. 1

Safety stands .................................................................. 2

Safety glasses ................................................................ 1

Air compressor or compressed air source ..................... 1

Spray bottle with dish soap/water solution .................... 1

Installing the Air Lift 1000 HD Kit

Missing or damaged parts? Call Air Lift customer

service at (800) 248-0892 for a replacement part.

STOP!

GETTING STARTED

1. Mark the upper and lower springs and spring seats with a china marker, tire marker

or white crayon to note its location (Fig. 1).

2. Remove the lower shock bolts from both shocks (Fig. 2).

g. 1

Mark spring

location in

reference to

upper and

lower spring

seat. Sample

of driver’s

(left) side

shown.

g. 2

MN-1081

Air Lift 1000 HD

3. Remove the brake line holder bolt from the Panhard (lateral bar) bracket behind the

passenger’s (right) side coil spring and pull line holder away from the bracket (Fig. 3).

Save the bolt for re-use.

4. Lift the vehicle up and support the frame with safety stands. Leave enough room to

drop the axle down low enough to remove the coil springs (Fig. 4).

5. Drop the axle down low enough so coil springs can be removed (axle hanging).

Remove one spring at a time for installing the air springs. If necessary, pull down on

the wheel or axle to create enough room for the springs to be removed.

6. With the spring removed, remove and discard the spring rubber isolator off the

middle of the coil spring (Fig. 5).

The rubber isolator at the top does not have to be removed.

g. 3

Remove

brake line

bolt and pull

line holder

away from the

bracket.

g. 4

g. 5

Leave top rubber

isolator on

spring.

Remove lower

rubber isolator

on the middle of

the spring.

NOTE

MN-1081

Air Lift 1000 HD

1. Cut the air line (C) in two equal lengths and install the straight pump connector (M)

and air line clamp (L) on one end of each air line. Remove the valve cap off the air

spring and screw the pump connector on the stem finger tight. Slide an air spring

protector (B) over each hose and onto the top of the air spring (A) (Fig. 6).

DO NOT USE ANY TOOLS TO TIGHTEN THE PUMP CONNECTOR OR DAMAGE TO

STEM WILL OCCUR.

2. Insert the air spring assembly into the top of the stock coil spring and push to the

bottom. Set the rubber upper spring seat on top of the spring assembly (if it fell out

of the upper spring seat when removing the coil spring) making sure the end of the

coil spring is positioned correctly in the mount (the end of the coil spring indexes into

the mount only one way).

There are small tabs on the rubber upper spring seat mount that go into holes in the upper

spring seat (Fig. 7).

NOTE

g. 6

g. 7

When installing

spring assembly,

make sure tabs

insert back into

the upper spring

seat holes that

align with them.

Installing the Air Springs

CAUTION

MN-1081

Air Lift 1000 HD

3. Insert the hose through the hole in the upper spring seat mount and reinstall the coil/air

spring assembly, making sure the mark (previously made in step one of getting started)

on the upper and lower portion of the coil spring aligns with the mark on the upper

and lower spring seats (Fig. 8). Slightly raise the axle up enough to seat the coil spring

into the upper and lower mounts and, as stated above, make sure the small tabs go

into the upper spring seat (Fig. 7). With the upper and lower spring seated, push the

protector up inside the upper rubber spring seat as far as possible. Repeat assembly

for the other side.

4. With both springs in position, raise the axle fully and reattach the lower shock bolts

(Fig. 2). Torque the lower shock bolts to 100 lb.-ft. (135Nm). Re-attach the passenger’s

(right) side brake line bracket and bolt previously removed and tighten securely (Fig. 3).

Remove the safety stands.

5. Using the zip ties (D) route the air lines above the frame and to the area back behind

the rear license plate. Above the coil springs, leave enough slack in the air lines for

suspension articulation.

A single-path air line installation is recommended for vehicles that typically have even weight

distribution (Fig. 9). If weight in the vehicle varies from side to side and unequal pressures

are needed to level the load, use a dual-path installation. For dual-path air line installations,

eliminate the tee fitting (J) and route separate air lines for both air springs (Fig. 10).

TO PREVENT THE AIR LINE FROM MELTING, MAINTAIN AT LEAST 6” (152MM) FROM

THE EXHAUST SYSTEM TO THE AIR LINE.

Installing the Air Lines

Single-path Air Line Routing

Dual-path Air Line Routing

g. 9 g. 10

g. 8

Align the marks

when installing

the spring

assemblies

CAUTION

MN-1081

Air Lift 1000 HD

1. If installing a single-path air line, choose a location for the tee fitting (J) on the wheel

well, license plate, or rear bumper. Determine and cut adequate length of air line (C)

to reach to the tee from left and right side air springs.

LEAVE SUFFICIENT AIR LINE SLACK TO PREVENT ANY STRAIN ON THE FITTING

DURING AXLE MOTIONS.

2. Use this procedure (Fig. 11) for all air line connections:

a. Slide the air line clamp (L) onto the air line (C).

b. Push the air line and air line clamp over the barbed stem so that the air line

covers all the barbs.

c. Compress the ears on the air line clamp with pliers and slide it forward to fully

cover the barbs.

3. Select a location for the Schrader valve (K), ensuring that the valve will be protected

and accessible with an air hose (Fig. 12). Determine and cut adequate length of air

line (C) to reach from the tee to the Schrader valve or from the air springs to the

valve if using a dual-path installation.

4. Drill a 5/16” (8mm) hole for the Schrader valve (K) and mount as shown (Fig. 13).

Install the air line on the Schrader valve first. The rubber washer (G) serves as an

outside weather seal.

DO NOT INFLATE THE AIR SPRINGS BEFORE READING THE MAINTENANCE AND USE

GUIDELINES IN THIS INSTALLATION GUIDE AS WELL AS THE USER GUIDE INCLUDED

WITH THIS KIT.

Hex nut (F)

Schrader

valve (K)

Vehicle

body

or bumper

Flat

washer (I)

Star washer (H)

Rubber washer (G)

Nylon

air line (C)

Air line

clamp (L)

Drill 5/16”

(8mm) hole

Hex

nut (F)

Valve

cap (E)

g. 13

Installing the Air Lines

g. 11

From the

left

air spring

From the

right

air spring

To Schrader

valve

g. 12

A. Inside fuel tank filler door C. License plate or

B. Inside rear wheel wells rear bumper area

MICHIGAN

XXX-XXX

www.MICHIGAN.gov

CAUTION

MN-1081

Air Lift 1000 HD

Before Operating

 Clearance test — Inflate the air springs to 25-35 PSI (1.7-2.4BAR) and make sure

there is at least 1/2” (13mm) clearance from anything that might rub against each air

spring.

 Leak test before road test — Inflate the air springs to 25-35 PSI (1.7-2.4BAR) and

use a soapy water solution to check all connections for leaks. All leaks must be

eliminated before the vehicle is road tested.



Heat test — Be sure there is sufficient clearance from heat sources, at least 6”

(152mm) for air springs and air lines. If a heat shield was included in the kit, install it.

If there is no heat shield, but one is required, call Air Lift customer service at

(800) 248-0892.

 Road test — The vehicle should be road tested after the preceding tests. Inflate the

air springs so that the vehicle is level. Drive the vehicle 10 miles (16km) and recheck

for clearance, loose fasteners and air leaks.

 Operating instructions — If professionally installed, the installer should review the

User Guide with the owner. Be sure to provide the owner with all of the paperwork

that came with the kit.

INSTALLATION CHECKLIST

Consult the included User Guide for information about fixing air leaks along with more

tips for maintenance and use before using the product.

MAINTENANCE AND USE GUIDELINES

1. Check air pressure weekly.

2. Always maintain normal ride height. Never inflate beyond 50 PSI (3.5BAR).

3. If the system develops an air leak, use a soapy water solution to check all air line

connections and the inflation valve core before deflating and removing the air spring.

FOR SAFETY AND TO PREVENT POSSIBLE DAMAGE TO THE VEHICLE, DO NOT EXCEED

MAXIMUM GROSS VEHICLE WEIGHT RATING (GVWR) OR PAYLOAD RATING, AS

INDICATED BY THE VEHICLE MANUFACTURER.

ALTHOUGH THE AIR SPRINGS ARE RATED AT A MAXIMUM INFLATION PRESSURE OF

50 PSI (3.5BAR), THE AIR PRESSURE ACTUALLY NEEDED IS DEPENDENT ON LOAD AND

GROSS VEHICLE WEIGHT RATING.

LIMITED WARRANTY AND RETURN POLICY

Air Lift Company provides a limited lifetime warranty to the original purchaser of its load support

products, that the products will be free from defects in workmanship and materials when used

on cars and trucks as specified by Air Lift Company and under normal operating conditions,

subject to the requirements and exclusions set forth in the full Limited Warranty and Return

Policy that is available at www.airliftcompany.com/warranty.

For additional warranty information contact Air Lift Company customer service.

Maximum Air PressureMinimum Recommended Pressure

50 PSI (3.5BAR)5 PSI (.34BAR)

CAUTION

MN-1081

Air Lift 1000 HD

Notes

Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or PO Box 80167 • Lansing, MI 48908-0167

Toll Free (800) 248-0892 • Local (517) 322-2144 • Fax (517) 322-0240 • www.airliftcompany.com

Thank you for purchasing Air Lift products — the professional installer’s choice!

Need Help?

Contact our customer service department by calling

(800) 248-0892. For calls from outside the USA or

Canada, our local number is (517) 322-2144.

www.airliftcompany.com/warranty

Printed in the USA

JJC-1018

California: WARNING: Cancer and Reproductive Harm – www.P65Warnings.ca.gov

Air Lift 60828HD Installation guide

Air Lift 60828HD Installation guide

Air Lift 60828HD Installation guide

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